Tapered fibrous sheet



Nav. 26, 1929.

M. KLlEFoTH TAPERED FIBROUS SHEET Filed oct. 2o, .192e 2 sheets-,sheet m MW www4,

ATTORNEYS N0V 26, 1929 y M. KLuaFoTl-l y 1,737,286

TAPERED FIBROUS SHEET l Fired oet. 2o. .192e 2 sheets-sheet a' INVENTOR ATTORNEYS MAX KLIEFOT, OF IIIADISON., WISCONSIN, ASSIGNOR TO C. F. BURGESS LABORATORIES,

Paeafea Nov. '26,1929

,UNITED vSTATES- OFFICE INC., AO1" MADISON, WISCONSIN, A CORPORATION OF DELAWARE 'herman rmnous SHEET Application tiled 0ctober 20, 1928. Serial No. 313,687.

. This invention relates to a fibrous material in the form of sheets of varying thickness such as tapered brous shingles and to a method of makingsuch ibrous material.

rlihis invention is an improvement over the process disclosed in the H. F. lVeiss application Serial No. 139,47 6 led October 4, 1926. One of the objects of my invention is to provide an improved continuous method for making a tapered fibrous shingle on a one cylinder machine. A further object of this in-V vention is to make a continuous fibrous sheet of successively increasing and decreasing thickness valong the machine direction of the sheet. It is still a .further object to provide a iibrous shingle in whichthe degree of taper may be varied at will.

Other objects, advantages and characteristic features will become apparent from the following description of my new product and process land from the accompanying drawings wherein:

Fig. 1 is a diagrammatic plan vview ofthe.

. apparatus 4 which is used to make one form of my improved fibrous sheet; y Fig. 2 is a vertical, sectional along line 2--2 of Fig. 1;

Fig. "3 is a portion of a sheet produced by' the apparatus of Figs. 1 and 2;

f ig'. 4 is adiagrammatic sideview of another ,machine used to make'another form of ibrous sheet;

Fig. 5 is a plan View 0f a sheet laid down view taken in accordance with the modiiicationshown in Fig. 4;

Fig. 6 1s anv exaggerated longitudinal sec-C I tion through a librous sheet before pressing and as laid down in accordance with the modiication of my improved method shown in Fig. 4;

Fig. 7 is an exaggerated longitudinal section through my double tapered board after pressing; v

Fig. 8 is a' reproduction of Fig. 7 with the contour of4 the board greatly exaggerated Fig. 9 isa greatly exaggerated longitudinal section through the board after ithas under'- gone a nal shapingand drying operation; 'Y Fig. 10 is a lside viewof a shaping and drying press roll; and

Fig. 11 is ya diagrammatic side view of a preliminary drier which may be included in the machines of Figs. 1, 2 and 4.

Although several methods are described in the'Weiss application for the production of tapered fibrous shingles, on the machine dev scribed thereiml have discovered a new and improved method for accomplishing the same This sheet is then cut at the lines of minimum and maximum thickness to produce tapered shingles.

The composition of and the method of-making my improved product can best be under stood by referring to the accompanying drawings in which likel numerals indicate like parts in .the several figures. The vat 1 ofa wet machine contains the slurry of water and pulp. The Vusual perforate cylinder'mould 2 picks up a web of pulp which is then car'- ried tocouch roll 3, around which felt 4 travels in the indicated direction. The wet pulp web is picked up and carried along on felt 4 from the p'erforate cylinder mould 2 and is then pressed by press roll 5. The moist. pulp web lis picked up by press roll 5 and is removed therefrom by doctor 6. This'pulp web may be creped by the doctor or may be kept smooth as desired. In ordner' to secure a high degree of smoothness, the web maw be arranged to be transferredlfrom roll 5 eoA to conveyor belt 7 without coming in coni tact with the doctor 6.' The pulp web 8 is then carried forward by a conveyor belt 7 which is part of a hinged reciprocating loop` ing device which is shown in another position by the dotted lines of Fig. 2. The off-take roll 9 of the hinged loopingdevice `works, along a guide 1'0 and distributes the pulp web 8A across v'the conveyor 11 as shown: Tightener roll 12 functions to keep conveyor belt 7l taut and directs the return travel of belt 7 along a path which is at alltimes as nearly as possible of the same length as the forward path. InFigs. 1 and 2 the pulp web is distributed transversely on the conveyor 11 which ismoving inthe direction of the Varrow of Fig. 1. In Fig. 4 the conveyor belt is moving parallel to the direction of pulp web 8.

The conveyor belt 11 moves at successively increasing and decreasing speeds by means of any suitable mechanism, such as `a cam. Because of the successively increasing and decreasing speeds t-he pulp webs are piled up in successively decreasing and increasing quantities as illustrated in Figs. 3, 5 and 6, the exposed fold edges being spaced at increasing and decreasing distances. By properly regulating the maximum and minimum speeds of conveyor 11 the degree of tap'er between points vof minimum4 and maximumA thickness may be varied at will.

The pulp web, when laid down transversely to the conveyor-11 of Figs. 1 and 2, forms a series of overlapping folds of pulp illustrated in Fig. 3, the distances between the edges varyingwith the speed of the conveyor, that is, increasing and decreasingregularly according to the increasing and decreasing speed of the conveyor 11. The folds may be eut at the folded edges Vas'shown by the arrows in Fig. 7 or may be used in the form shown- TheA folded edges come at the edge of the fibrous sheet but are not parallel to it and must be trimmed. It is necessary to proportion the width of the pulp web to the length of the taper and the speed 'of the conveyor 11. The fibers when laid down transversely are at an angle greater than 45 to the machine direction of conveyorl 11, and are substantially at right angles to it. A brous sheet or board made in this manner has greater strengtlracross the sheet than with the machine direction.

If the foldsof pulp web arelaid down parallel to the machine direction by the machine of Fig. 4, the folded edges are across the sheet as shown in Fig. 5. The folds of pulp web made by this method extend from one surface of the fibrous sheet diagonally through to the; other surface.

The fibrous sheet or board formed by laying down the folds of pulp web parallel. or'

transversely tothe direction of the conveyor 1.1, vor in any other predetermined manner as may seem desirable, usuall passes through a continuons press 1 3, Whic may be in the form of press-rolls. This operation compresses the loosely piled overlapping folds of pulp web into a homogeneous and coherent moist fibrous sheetor board. If the paper has been creped by doctor 6, thev pressure of rolls or other press 13 interlccks the creped paper surfaces to form a fibrous sheet'in which the overlapping folds adhere at their surfaces with greater tenacity thanfwhen the moist webs are not creped. The moist fibrous sheet may either be dried or used as a moist pulp product without drying after leaving4 the continuous press 13. If the product is t0- be dried the sheet then passes through drier 14, after which it may pass through trimmer 15 and cutter 16. f

A board made in the manner outlined above presents a longitudinal contour which is rounded at the points of maximum and minimum thickness, as illustrated in an exaggerated manner in Fig. 8. For shingles it is desirable that the tapered surface proceed .in a uniform plane from the line of maximum may eut the continuous sheet at lines of minimum thickness only. The cuter 16 may be followed by a conveyor traveling at right angles to the previous direction of travel.

This latter conveyor may carry the tapered double sheets through heated press rolls 21 and 22, as shown in Fig. 10. The upper rolls 21 are inclined at an angle conforming with the taper of' the sheet and have uniform downward pressure acting upon `Atheir bearings. These press rolls exert a shaping action upon the sheet in addition to a pressing and drying action. "lhe tendency of the contour of vthe sheet to become rounded at points of maximum and minimum thickness is thus corrected and a product is secured which possesses the desired plane surfaces and sharp angles.

For practical purposes, preliminary drier- 17 as shown in Fig. 1l,l may be interposed between felt 4 and conveyor 7 of the machine shownnn Figs. 1, 2 and 4.V The moist pulp web winds over a plurality ofrolls 18. During the passage through drier 17 the web is maintained in contact with a stream of warm dry air which enters at inlet pipe 19 and exhausts at the outlet pipe 20. The drier is arranged to remove a portion, approximately 20%, of the moisture contained in the web. Precautions must be observed not to remove too much moisture since that will reduce the coherence of the resulting sheet. The preliminary drier is employed because moisture can be removed more efficiently from a single Web than from a thick sheet.

Ifthe sheet is to be made of water-resisting asin the production of asphalt shingles, the

`finely divided Water-resistant material may be suspended in the slurry of water and pulpl in vat 1 of the Wet machine. The perforate cylinder mould 2will then pick up a web of' pulp and wate1resistant material. The pulp web 8 will contain the water-resistant nia-` terial, such as asphalt, and the built up board will have it disseminated throughout. In an-' other method, as described in the Weiss application, the water-resistant compound may vbe dusted or sprayed in finely divided form lon the pulp web 8. A suitable device for this 'purpose is illustrated diagrammatically at 8 in Fig. 2 of the drawings. `In such a method,`better adherence between the waterresistant compound and the wet web is secured if a small amount of water-resistant compound has been previously incorporated in the slurry in vat 1. The overlapping pulp folds containing the water-resistant comf .poundbsuch as asphalt are then passed through heated ress-rolls to dry the pulp and melt the wa er-resistant compound andv thereby thoroughly saturate the fibrous sheet or board. The board may be given a further coating of water-resistant compound followed by a layer of crushed rock to complete-the shingle surface.

Throughout the claims the term folds is l used to define, not only the folded edge, but the entire overlapping portions formed by sheet successivelyvincreasing and decreasing in thickness along the machine direction of said sheet, comprising overlapping folds of pulp -web havingvedges extending in transverse relation to the machine direction of said sheet, said edges being spaced from each other .in the machine direction of. the finished sheetm successlve series of decreaslng and m-\ creasing distances. 1 t

2. As an article of lmanufacture a fibrous sheet successively increasin and decreasing in thickness along the mac ine direction of said sheet, 4comprising overlapping creped folds o f 'pulp web having edges extending in transverse relation to the machine direction of vsaid sheet, said edges being spaced from each other in the machinedirectionof the finished sheet in successive series of decreasing and increasing distances.

3. As an article of manufacture, a papel- 4boardsuccessively increasing and decreasmg in thickness along the 'machine direction of said board, comprising a pressed sheet, of overlapping folds of paper-stock web having edges extending in transverse relation to the machine direction of said board, said edges being spaced from each other in the machine direction of the finished board in successive series of decreasing and increasing distances.

4. Ag an articlepf manufacture, a paperf board successively increasing and decreasing in thickness along the machine direction of lsaid board, comprising a pressed sheet of overlapping folds formed from a single web ofv paper-stock having edges extending in transverse relation to. the machine direction of said board, said edges being spaced from eachV other in the vmachine direction vof the finished board in successivel series of de- Jcreasing and increasing distances.`

5. As an article ofmanufacture, a paper board successlvely increasmg and decreasing.

in thickness along the machine directionl of said board, comprising a pressed sheet of 4overlapping folds of paper-stock web having edges extending in transverse relation to the machine direction of said' board, said edges being spaced fromveach other in the machine direction of the finished board in successive series of decreasing and increasing distances,

the majority'of the fibers of'said board being at an angle greater than 45 to the machine direction of said board.

6. As an article of manufacture, a coherent paper board successively increasing and def' -creasing in thickness along the machine d1re'c tion of said board, comprising a pressed sheet of overlapping folds of pulp web. having edges extending inv transverse relation to the machine direction of the sheet, said edges being spaced from eachv other in the machine 'direction of the finished board in successive series .of decreasing and increasing distances and having the constituent folds at an angle to the finished surfaces. b l

7. As an article ofmanufacture a fibrous sheet successively increasing and decreas- Y ing in thickness along the machine direction ofsaid sheet and having the constituent fibrous webs at an angle to `the finished 'surfaces. I

8. -As an article of manufacture a waterwresistant fibrous sheet successively increasing and decreasing in thickness along the -machine direction of said sheet and having the constituent fibrous webs at an angle to the finished surfaces.

9. As an article of manufacture an asphalt saturated fibrous sheet successively increasing and decreasingv in thickness along the machine direction of said sheet and having the constituent fibrous webs at an angle to the finished surfaces.

10. As an article of manufacture a fibrous sheet successively increasing and decreasing in thickness along the machine direction of said sheet. 7 c

v 11. AS `an article of `manufacture a coherent. paper board successively increasing and decreasing in thickness along the machine direction of said board.

12. The method of making a fibrous sheet successively increasing and decreasing in thickness which comprises laying down overlapping folds of moist pulp webs on a conant material, spraying ^said moist web. with veyor moving at successively decreasing and an additional quantity of water-resistant increasing speeds and then pressing said material, layingvdown said moist web conmoist pulp webs into a coherent sheet. tinuously on a conve or 4moving atsucces- 13. The step in the method of making a sively decreasing an increasing speeds to `fibrous sheet successively increasing and deform overlap ing folds, pressing-and heatcreasing in thickness which comprises lay-b ing said over apping Webs to dry, bind and ing down overlapping folds of moist pulp saturate said Webs with said water-resistant webs on a conveyor moving at successively material. and form a. coherent sheet, and cutdecreasing and increasing speeds. ting said pressed sheet into short lengths 14. The method of making a fibrous sheet along the lines of maximum and minimum' successively increasing and decreasing in thickness. thickness which comprises laying down a 20. The method of making tapered shinmoist pulp web continuously and transversegies vvhieh comprises forming a suspension of ly on a conveyor moving at successively depulp and finely divided water-resistant macreasing and increasing speeds to Vform overterial, forming a moist weh from said pulp, lappingr folds, and pressing said pulp Webs partially drying said moist web, laying down into acoherent sheet. said partially dried web continuously on a 15. The method of making a fibrous sheet conveyor moving at successively decreasing successively increasing and decreasing in and increasing speeds to'form overlapping thickness which comprises partially drying folds, pressing said overlapping, partially a moist pulp web, laying down said pardried 'folds to form a coherent sheet, drying tially dried web upon a conveyor moving at said prefizsed sheet, and cutting said driedsheet successively decreasing and increasing into short lengths along lines of maximum speeds to form overlapping folds, and pressand minimum thickness. ing said overlapping folds into a coherent 2l. 'lhe steps in the method of making a sheet. uniformly tapered shingle which comprise 16. The method of making a fibrous sheet laying down a Vmoist pulp web continuously having uniformly tapered plane surfaces on a conveyor moving at successively decreas- Which comprises laying down a moist pulp ing and increasing speeds to form overlapweb on a conveyor moving at successively deping folds, pressing said pulp webs into a eocreasing and increasing speeds to form overherentsheet, cutting said pressed sheet into lapping folds, pressing said pulp webs into individual lengths along uthe lines of minia coherent sheet, and heating and pressing muni thickness, pressing and heating said said sheet to remove the moisture therefrom individual lengths to dry said lengths and to and to form plane tapered .surfaces thereon. form plane tapered surfaces thereon, and cut- 17. The steps in the method of making tating said individual lengths along the lines of pered shingles which comprise-laying down maximum thickness. a moist pulp web continuously on a con- 22. In a machine for making a fibrous taveyor moving at successively decreasing and' Pei-ed sheet the combination of means for increasing speeds to form overlapping folds, forming overlapping folds of pulp Webs and pressing said pulp Webs into a coherent means for spacing said folds in the machiney sheet, and cutting said pressed sheet into direction of thefinished sheet in a series of short lengths along the lines of maximum regularly increasing and decreasing disand minimum thickness. tances.

18. The method `of making water-resi'st- 23. In a machine for making a fibrous taant, tapered shingles which comprises form, pered sheet, the combination of means for laying a suspension of pulpand finely divided ing dOWn a mOiSt pulp Web in Overlapping Water-resistant material, forming a continufolds, means for spacing said folds in the ma ous moist web from said pulp and water-re; chine direction of the finished sheet in a series sistant material, laying downl said moist of regularly increasing" and decreasing dis- Web continuously on a conveyor moving at tances, and means for pressing said succession successively decreasing and increasing 0f OldSlntO aCOhe-Ient Sheet.

speeds to form overlapping folds, pressing 24:. In a machine for making a fibrous taand heating said overlapping Webs to dry, pered sheet, the combination of means for' bind and saturate said Webs with said Water- Crepng mOiSt pulp Web, means for laying resistant material and form a coherent, sheet, down said creped web in Overlapping folds. and cutting said pressed sheet, into short means fOI SplCiIl'g Said folds in the machine lengths along the lines of maximum and ydirection of; the finished sheet in a series of minimum thickness, regularly increasingand decreasing distances,

19. The method of making water-resistant and means for pressing Said folds into a C0- tapered shingles which comprises forming a bereut sheet. n suspension-of pulp and finely divided Water- 25. In a machine for making a fibrous taresistant material, I wforming a continuous pered'sheet, the combination of means for parmofst web from s aid pulp and water-resisttially drying a moist pulp web, means for laying down said partially dried web in ovehlapping folds, means for spacing said folds in the machine direction ofthe finished sheet in a. series of regularly increasing and decreasing distances, and means for pressing said folds into a coherent sheet.

26. A machine for making a fibrous tal ered sheet com risin means for formin P a P g said moist web, means for laying down sald partially dried web in overlapping folds, means for spacing said folds in the machine direction of the finished sheet in a series of regularly increasing and decreasing distances,

a' moist pulp web, means for partially drying means for pressing said folds into a coherent sheet, and means for drying said sheet. 27. A machinefor making fibrous, waterresistant tapered shingles which includes the combination of means for forming moist Webs of pulp and nely divided water-resistant material, means for partially drying said moist Webs, means for spraying additional waterresistant material upon said partially dried webs, means for laying down said treated Webs in overlapping folds, means for spacing said folds in the -machine direction of the resulting sheet in a seri/es of regularly increasing and decreasing distances, means' for pressing said folds into ,a coherent sheet, means or drying said sheet, and means for cutting said dried sheet along the lines of maximum and minimum thickness.

pered sheet, a conveyor 28. In a machine for making a fibrous tapered sheet, a conveyor adapted to be driven yat varying speeds, a moist pul) lapping fol s d l 29. In a machine for makinga fibrous ta- Web on said conveyor in overat varying speeds,

and a reciprocating device adapted to x` my signature,

In testimony. whereof I a v MAX KLIEFOTH.,

and means for laying down adapted to be driven feeding deliver a moist pulp web to said conveyor in overlappin folds. 

